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EXHAUST SYSTEM


B ENGINE

                                                                                                                                                         A




                                                                                             SECTION
                                                                                           EXHAUST SYSTEM
                                                                                                                       EX                                EX



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                                                            CONTENTS
PREPARATION .......................................................... 2
                                                                 .           Components ............................................................ 3
                                                                                                                                               .         F
 Commercial Service Tools ....................................... 2
                                                                 .           Removal and Installation ......................................... 4
                                                                                                                                               .
EXHAUST SYSTEM .................................................. 3
                                                                 .            REMOVAL ............................................................ 4
                                                                                                                                               .
 Checking Exhaust System ...................................... 3.            INSTALLATION .................................................... 4
                                                                                                                                               .         G
                                                                              INSPECTION AFTER INSTALLATION ................. 5                .

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Revision: 2006 December                                               EX-1                                                     2006 FX35/FX45
                           PREPARATION

PREPARATION                                                                       PFP:00002

Commercial Service Tools                                                             NBS004IM



 Tool name                                       Description

 Power tool                                      Loosening nuts and bolts




                                     PBIC0190E




Revision: 2006 December       EX-2                                          2006 FX35/FX45
                                         EXHAUST SYSTEM

EXHAUST SYSTEM                                                                                        PFP:20100
                                                                                                                        A
Checking Exhaust System                                                                                      NBS004IN


Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.                                                                                 EX
q   If anything is found, repair or replace damaged parts.

                                                                                                                        C


                                                                                                                        D

                                                                                                          SMA211A

                                                                                                                        E
Components                                                                                                   NBS004IO


CAUTION:
q  Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat                     F
   resistance, corrosion resistance, and shape.
q  Perform the operation with the exhaust system fully cooled down because the system will be hot
   just after engine stops.
                                                                                                                        G
q  Be careful not to cut your hand on the heat insulator edge.
                                                  VQ35DE
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                                                                                                     PBIC1583E

  1.   Main muffler                 2.   Mounting rubber             3.   Main muffler mounting bracket
  4.   Mounting rubber              5.   Center muffler              6.   Gasket
  7.   Exhaust front tube           8.   Gasket                      9.   Collar

Revision: 2006 December                             EX-3                                     2006 FX35/FX45
                                            EXHAUST SYSTEM

     10. Grommet                       11. Exhaust mounting bracket   12. Grommet
     13. Mounting rubber               14. Bracket                    15. Ground cable
     16. Ring gasket

                                                      VK45DE




                                                                                                      PBIC5097E

     1.   Main muffler                 2.   Mounting rubber           3.   Main muffler mounting bracket
     4.   Mounting rubber              5.   Center muffler            6.   Dynamic damper
     7.   Gasket                       8.   Exhaust front tube        9.   Gasket
     10. Mounting bracket              11. Exhaust mounting bracket   12. Collar
     13. Grommet                       14. Grommet                    15. Mounting rubber
     16. Bracket                       17. Ground cable               18. Ring gasket

Removal and Installation                                                                                     NBS005S5

REMOVAL
q     Disconnect each joint and mounting using power tool.
q     When removing main muffler, remove main muffler mounting bracket bolts.
q     Remove exhaust mounting bracket as follows:
1.    Remove engine rear undercover.
2.    Remove front cross bar. FSU-6, "FRONT SUSPENSION ASSEMBLY" .
3.    Remove exhaust mounting bracket.
INSTALLATION
Note the following, and install in the reverse order of removal.




Revision: 2006 December                                EX-4                                   2006 FX35/FX45
                                       EXHAUST SYSTEM

q   Tighten main muffler mounting bracket bolts in numerical order
    as shown in the figure.                                                                                   A


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                                                                                                              C

                                                                                                  PBIC1049E

                                                                                                              D
CAUTION:
q  Always replace exhaust tube gaskets with new ones when reassembling.
q  If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat     E
   insulator, remove them.
q  When installing heat insulator avoid large gaps or interference between heat insulator and each
   exhaust pipe.                                                                                              F
q  Remove deposits from the sealing surface of each connection. Connect them securely to avoid
   gases leakage.
q  Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-             G
   cle side. Check each part for unusual interference, and then tighten them to the specified torque.
q  When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
   left directions.                                                                                           H
INSPECTION AFTER INSTALLATION
q   Make sure clearance between tail tube and bumper is even.
                                                                                                               I
q   With engine running, check exhaust tube joints for gas leakage and unusual noises.
q   Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
    stress. Improper installation could result in excessive noise and vibration.
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Revision: 2006 December                          EX-5                                     2006 FX35/FX45
                          EXHAUST SYSTEM




Revision: 2006 December        EX-6        2006 FX35/FX45



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